Aluminum boron carbide composite and method to form said composite

ABSTRACT

An improved aluminum-boron carbide (ABC) composite has been discovered that is comprised of a continuous network of AlB 24 C 4  and boron carbide grains having therein other isolated aluminum-boron carbide reactive phases and at most 2% by volume of isolated metal. The improved ABC composite may be formed by forming boron carbide particulates into a porous body that has a porosity of at most about 35%, where the boron particulates have been heat treated to a temperature of 1200° C. to 1800° C., infiltrating the porous body with aluminum or aluminum alloy until an infiltrated aluminum-boron carbide body is formed that has at most about 1% porosity, heat treating the infiltrated body for at least 25 hours at 1000° C. to 1100° C. to form an aluminum boron carbide composite having a continuous network of AlB 24 C 4  and boron carbide, and subsequently heat-treating to 700° C. to 900° C. to form the improved aluminum boron carbide composite.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional of application Ser. No. 12/575,090filed Oct. 7, 2009, which claims the benefit of U.S. Provisionalapplication No. 61/108,570, filed Oct. 27, 2008.

FIELD OF THE INVENTION

This invention relates to aluminum boron carbide composites.

BACKGROUND OF THE INVENTION

Infiltrated aluminum-boron carbide (ABC) composites are known. They havebeen proposed as a replacement for costly hot pressed boron carbideceramics. In making high ceramic content ABC composites, the aluminummust be reacted to form aluminum boride, aluminum borocarbide oraluminum carbide ceramic phases. Unfortunately, the ABC composites madeto date have suffered from the need to start with expensive fine boroncarbide powder or lack of impact strength due to the ceramic phasesformed not providing a strong hard impact resistant composite that canprovide the wear of a ceramic.

Accordingly, it would be desirable to provide a material that overcomesone or more of the problems of the prior art such as one of thosedescribed above. It would also be desirable to provide a method ofpreparing the material.

SUMMARY OF THE INVENTION

A first aspect of the invention is an improved aluminum-boron carbidecomposite comprised of a continuous network of AlB₂₄C₄ and boron carbidegrains having therein other isolated aluminum-boron carbide reactivephases and at most 2% by volume of isolated metal. A second aspect ofthe present invention is a method for preparing the improvedceramic-metal composite of the first aspect, the method comprising,

a) forming boron carbide particulates into a porous body that has aporosity of at most about 35%, wherein prior to step (b) the boronparticulates are heat treated at a temperature of about 1200° C. toabout 1800° C. in a vacuum or inert atmosphere for one minute to 50hours,

b) infiltrating the porous body with aluminum or aluminum alloy until aninfiltrated aluminum-boron carbide body is formed that has at most about1% porosity,

c) heat treating the infiltrated body for at least 25 hours at anAlB₂₄C₄ forming temperature of about 1000° C. to about 1100° C. to forman aluminum boron carbide composite having a continuous network ofAlB₂₄C₄ and boron carbide, and

d) subsequent to step (c) heat-treating at an aluminum depletingtemperature of about 700° C. to about 900° C. for a time to form theimproved aluminum boron carbide composite having an aluminumconcentration of less than 2% by volume of said composite.

Surprisingly, the method according to the invention produces aceramic-metal composite that has excellent strength, stiffness andimpact resistance even when using large boron carbide particulates(e.g., 10, 20, 50, 100 micrometers or more in diameter).

The ceramic-metal composite may be used in applications benefiting fromproperties such as low density, high stiffness and impact resistance.Examples of components include hard drive components (e.g., E-blocks,suspension arms, disks, bearings, actuators, clamps, spindles, baseplates and housing covers); brake components (e.g., brake pads, drums,rotors, housings and pistons); aerospace components (e.g., satellitemirrors, housings, control rods, propellers and fan blades); pistonengine components (e.g., valves, exhaust and intake manifolds, camfollowers, valve springs, fuel injection nozzles, pistons, cam shaftsand cylinder liners) and other structural or recreational components(e.g., bicycle frames, robot arms, deep sea buoys, baseball bats, golfclubs, tennis rackets and arrows). Mining & oil well components, forexample rock drilling bits, coring bits, auger drilling bits, hydraulicdrilling bits, reverse circulation drilling bits, percussion drillingbits and sonic drilling bits.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a 50× magnification optical micrograph with a line drawnthrough the continuous network of the composite of this invention.

DETAILED DESCRIPTION OF THE INVENTION The ABC Composite

The aluminum-boron carbide (ABC) composite is comprised of a continuousnetwork of AlB₂₄C₄ and boron carbide grains. It is understood that theAlB₂₄C₄ and boron carbide (B₄C) may as well understood in the artdeviate from stoichiometry (solid solution) and still encompass theinvention. For example, the B/Al ratio of the AlB₂₄C₄ is typically atleast 15 by mole. A continuous network of AlB₂₄C₄ and B₄C grains meansthat individual grains of boron carbide are bonded through the AlB₂₄C₄phase. Thus, starting from one surface of the ABC composite, one cantrace an unbroken path to the opposing surface through the AlB₂₄C₄ andB₄C phases as shown in FIG. 1. This may be determined by using knownmetallographic techniques (e.g., see Underwood in QuantitativeStereology, Addison-Wesley, Reading, Mass. (1970)).

Generally, the amount of boron carbide phase or grains is at least about40% by volume of the ABC composite, but may be at least about 45%, 50%,55%, 60% or 65% to at most about 90%, 85%, 80% or 75% by volume of theABC composite. The amount of AlB₂₄C₄ phase or grains is typically atleast about 10% by volume of the ABC composite, but may be at leastabout 15%, 20%, 25% or 30% to at most about 50%.

The ABC composite also contains isolated aluminum-boron carbide reactivephases and at most 2% by volume of isolated metal. The isolated metal isaluminum or a metal that is present in an aluminum alloy used to makethe ABC composite (e.g., alloying metals such as Cu, Fe, Mg, Si, Mn, Crand Zn). Desirably, the amount of free metal is as low as possible andmay be at most 2%, 1.75%, 1.5% or 1% by volume of the ABC composite. Theamount of aluminum may be determined, for example, using differentialscanning calorimetry (DSC). Isolated means that one can not trace anunbroken path to the opposing surface through the metal and otheraluminum-boron carbide reactive phases.

Other reactive phases means phases other than AlB₂₄C₄ that are formed bythe reaction of the metal and boron carbide used to form the ABCcomposite. Examples of such other reactive phases are AlB₂, Al₃₋₄BC,Al_(0.84)B_(39.8)C₄, AlB₁₂, Al₄C₃ and Al₈B₄C₇. The amount of otherreactive phases is typically at most about 25% by volume of the ABCcomposite, but may be at most about 20%, 15, 10 or 5% by volume of theABC composite.

The metal is aluminum and alloys of aluminum, such as those that containone or more of Cu, Mg, Si, Mn, Cr and Zn. Exemplary aluminum alloysinclude Al—Cu, Al—Mg, Al—Si, Al—Mn—Mg and Al—Cu—Mg—Cr—Zn. Specificexamples of aluminum alloys include 6061 alloy, 7075 alloy and 1350alloy, each available from the Aluminum Company of America, Pittsburgh,Pa.

In general, the ABC composite has a density of at least about 90% oftheoretical density. Preferably, the composite has a density of at leastabout 95%, more preferably at least about 98%, even more preferably atleast about 99% and most preferably essentially 100% of theoreticaldensity. The ABC composite generally has a stiffness (i.e., Young'smodulus) equal to or greater than a composite made not having theaforementioned continuous network (i.e., a composite made with samestarting materials but not subject to processing to form said network).Preferably, the ceramic-metal composite has a stiffness greater than acomposite made lacking the continuous network. Likewise, this is thesame with respect to impact resistance of the ABC composite.

In a preferred embodiment, the ABC composite preferably has boroncarbide grains that have an average grain size that is 25 micrometers indiameter or greater, and even 30, 40, 50, 60, 70, 80, 90, 100, 125, 150,175, 200, 225 or 250 micrometers in diameter.

Forming of the ABC Composite

The ABC composite may be made by infiltrating a porous body comprised ofboron carbide powder with an aluminum metal, alloy thereof, orcombination thereof.

The boron carbide powder used to make the porous body is baked prior toor may be baked after being formed into a porous body at a temperatureof 1200° C. to 1800° C. in a vacuum or inert atmosphere for a time ofabout 1 minute to 50 hours. It is preferable to do such baking after theporous body has been formed when using a substantial amount of largerboron carbide particulates (e.g., greater than 50 micrometers), forexample, to increase the strength of the porous body. The particulartemperature and time is dependent on the particular boron carbide powder(e.g., size and size distribution) and is generally chosen to be theshortest time and lowest temperature so that undesirable phases andreactivity does not occur during infiltration. The baking temperature istypically at most about 1700° C., but may be at most about 1600° C.,1550° C., 1500° C., 1450° C. or 1400° C. to typically at least about1225° C., 1250° C. or 1300° C. The time is typically at least about 30minutes to several hours (2-4 hours).

Herein when an atmosphere is specified as a “vacuum or inertatmosphere”, it is understood to mean that the gaseous species presentin the atmosphere or vacuum is such that no appreciable reaction takesplace between such gaseous species with the boron carbide or aluminum atthe conditions experienced under that atmosphere. No appreciablegenerally means that at most no more than 0.5% of the boron carbide oraluminum is reacted with a gaseous species in the atmosphere provided.Generally, inert atmosphere may be any of the noble gases or a vacuumthat has a pressure of no greater than about 1 millitorr.

The porous body to be infiltrated must have a porosity no greater thanabout 35% so that the continuous network may be formed uponheat-treating. The porosity, however, should not be so small such thatthe aluminum is not able to infiltrate to make dense infiltrated ABCcomposite. Generally the porous body has a porosity of at most about34%, 33%, 32%, 31%, 30%, 29%, 28%, 27%, 26%, 25%, 24%, 23%, 22%, 20%,19%, 18%, 17%, 16% or even 15% to at least about 5%.

The boron carbide powder may have any useful average particle size suchthat an infiltrated ABC composite may be made with less than about 1%porosity. Generally, this means that there are sufficient amount ofsmall particles to ensure sufficient infiltration of the aluminum metaland to react to form the AlB₂₄C₄. In general, this means that the boroncarbide particles making up the porous body have a specific surface areaof at least about 0.5 m²/g. Typically, this means that at least about10% by weight of the porous body is made up of boron carbide particlesthat are less than 50 micrometers in diameter and more typically atleast about 10% of the porous body is made up of particles that are lessthan 45, 40, 35, 30, 25, 20, 15, 10 or even 5 micrometers in diameter.

In one embodiment, the porous body of boron carbide particulates isformed using at least two powders having different average particlesizes where the average size of the larger powder is at least 2 timesand preferably, 3, 4, 5, 6, 7, 8, 9 or even 10 times or more larger. Forexample, the particle size of the large boron carbide powder may have anaverage particle size by weight of 100 to 5000 micrometers and thesmaller boron carbide powder may have an average particle size by weightof 0.1 to 50 micrometers. When making a composite with such larger andsmaller particles, the finer particles act to ensure the infiltrationand formation of the AlB₂₄C₄ phase and the larger particulates increasethe toughness or impact resistance of the final ABC composite. Particlediameter is understood to mean equivalent spherical diameter.

In general desirable weight ratios of particles greater than 50micrometers in diameter to those less than 50 micrometers in diameter is(>50/<50) is at least 1/1, but may be at least 3/2, 2, 5/2, 3, 7/2, 4,5, 6, 7, 8, 9, or even 10. The particular useful ratio may depend on theamount of much finer particles (e.g., less than about 10 micrometers indiameter) because of these particles greater contribution to the surfacearea of the porous body.

The boron carbide powder used to make the porous body may be mixed byany suitable method such as those known in the art. Examples of suitablemethods include ball milling, attrition milling, ribbon blending,vertical screw mixing, V-blending and fluidized zone mixing. Ballmilling in a solvent such as ethanol, heptane, methanol, acetone andother low molecular weight organic solvents with milling media, such asboron carbide media, generally provides satisfactory results. Otheradditives useful in the formation of the porous body from the mixturemay be included such as dispersants, binders and solvent.

Suitable methods to form the porous body for infiltrating include, forexample, shaping methods such as slip or pressure casting, pressing andplastic forming methods (e.g., jiggering, injection molding andextrusion). The forming of the porous body may include removing, ifnecessary, solvent and organic additives such as dispersants and bindersafter shaping of the mixture. Each of the above methods and steps aredescribed in more detail in Introduction to the Principles of CeramicProcessing, J. Reed, J. Wiley and Sons, N.Y., 1988.

After the porous body of boron carbide particulates are formed, it isinfiltrated by aluminum, aluminum alloy or combination thereof.Infiltration is the process in which a liquid metal fills the pores ofthe porous body in contact with the metal. Infiltration of the porouspreform may be performed by any convenient method for infiltrating ametal into a preform body, such as vacuum infiltration, pressureinfiltration and gravity/heat infiltration provided that the atmosphereis essentially inert to the metal and components of the porous body(e.g., vacuum or inert gas such as a noble gas). Examples of suitableinfiltration methods are described by U.S. Pat. Nos. 4,702,770 and4,834,938, each incorporated herein by reference. After theinfiltration, a composite is formed that has at most about 1% porosity.The composite at this stage does not have a continuous network and needsto be further heat-treated to form such network.

Infiltration is preferably performed at a temperature where the metal ismolten but below a temperature at which the metal rapidly volatilizes.For example, when infiltrating aluminum or an alloy thereof into theporous body, the temperature is preferably at most about 1300° C., andmore preferably at most about 1200° C. and preferably at least about750° C., more preferably at least about 900° C., even more preferably atleast 1000° C. and most preferably at least about 1100° C. Theinfiltration time may be any time sufficient to infiltrate the porousbody to form an infiltrated ABC body and may range, for example, from 5minutes to 24 hours or more.

After the infiltrated ABC body is formed it is first heat treated for atleast 25 hours at an AlB₂₄C₄ forming temperature of 1000° C. to 1100° C.to form an aluminum boron carbide composite having a continuous networkof AlB₂₄C₄ and boron carbide. The temperature is critical as well so asto avoid deleterious phases and to ensure the formation of thecontinuous network. The time of 25 hours is, generally, the necessaryamount of time to ensure the continuous network, but it may be longer tofurther improve the properties and make the network more extensive, butat some point, the time need not be longer, because little or no furtherreaction takes place (e.g., 1000 hours or less). A second subsequentheat-treatment then needs to be performed to reduce the free metal torealize the ABC composite of this invention.

The second heat-treating is at an aluminum depleting temperature ofabout 700° C. to about 900° C. for a time to form the improved aluminumboron carbide composite having an aluminum concentration of less than 2%by volume said composite. The time may be any sufficient to reduce theamount of metal (e.g., aluminum or aluminum alloy) to less than 2% byvolume of the composite. Typically, this is at least about 30 minutes to100 hours, but may be at least 1, 2, 3 or 4 hours to at most about 50,25 20, 15, or 10 hours. The atmosphere for the first and secondheat-treatments may be a vacuum, inert atmosphere or in a particularembodiment in reactive atmospheres such as oxygen or air if thecomposite is encapsulated. Such an encapsulation may be realized byusing an excess of infiltrant metal such that the body is encapsulatedby the excess metal sealing it from the atmosphere when heat-treating.

Below are specific examples within the scope of the invention andcomparative examples. The specific examples are for illustrativepurposes only and in no way limit the invention described herein.

EXAMPLES Example 1

A ceramic-metal composite was made by first mixing boron carbide powdersF80 grit, F400 grit and F1500 grit in mass ratio 55:35:15.

The porous body was placed on a graphite setter and baked under argonatmosphere for ≧30 minutes at a temperature ≧1200° C. The baked porousbody was placed on a piece of aluminum in a refractory crucible. Thisassemblage was placed in a furnace. The furnace was heated to 1160° C.and maintained at that temperature for about 3 hours under vacuum toinfiltrate the porous body with aluminum.

The infiltrated body was first heat treated at 1050° C. for 50 hours inair.

The first heat-treated body was further heat treated at 800° C. for 100hours in air.

The improved composite that was formed had a metal content of <2%,stiffness, hardness and impact resistance as shown in Table 1. Theimpact resistance is assessed after dropping a 4 pound load from aheight of 5 inches on to a plate of material having surface area ofabout 9 to 16 square inches, i.e., plate of about 3″-4″ by 3″-4″, andareal density of ˜4.5 lbs/sq-ft). The microstructure is shown in FIG. 1,where the continuous network is readily shown.

Example 2

In Example 2, an improved ceramic-metal composite was made by the samemethod of Example 1, except the heat treatment parameters were changed.

The infiltrated body was first heat treated at 1050° C. for 100 hours inair.

The first heat-treated body was further heat treated at 800° C. for 50hours in air.

The resultant ceramic-metal composite's characteristics are shown inTable 1.

Example 3

In Example 3, an improved ceramic-metal composite was made by the samemethod of Example 1 except that the boron carbide powders were differentand initial heat treatment was heat-treated at 1050° C. for 100 hours inair as shown in Table 1. The resultant ceramic-metal composite'scharacteristics are shown in Table 1.

Comparative Example 1

In Comparative Example 1a ceramic-metal composite was formed by the sameprocess as described in Example 1 except that no heat-treatment wasperformed. This composites characteristics are shown in Table 1.

Comparative Example 2

Comparative Example 2 is a commercially available sintered siliconcarbide available under the tradename Hexoloy SA, available fromSaint-Gobain Ceramics, Structural Ceramics Group, Hexoloy® Products, 23Acheson Drive, Niagara Falls, N.Y. 14303. The characteristics of thisceramic are shown in Table 1.

Comparative Example 3

Comparative Example 3 is a commercially available alumina availableunder the tradename CoorsTek CeraShield® CAP3 alumina, available fromCoorsTek, 600 Ninth Street, Golden, Colo. 80401 USA. The characteristicsof this ceramic are shown in Table 1 as well as the impact resistance.

From Table 1, it is clear that the impact resistance is improvedcompared to a like boron carbide composite that does not have thecontinuous network and low aluminum content (Examples 1-3 versusComparative Example 2). Likewise, the hardness and stiffness of theinventions composite has much improved hardness and stiffness comparedto a composite having substantial amounts of aluminum (Examples 1-3 v.Comparative Example 1. The higher hardness along with excellent impactresistances would exhibit improved wear and durability than a compositewith substantial amounts of aluminum.

TABLE 1 Density of 1^(st) 2^(nd) Porous heat heat Density 1st 2nd 3rd1st 2nd 3rd Body treat- treat- of Hard- Stiff- B₄C B₄C B₄C B₄C B₄C B₄C(% of ment ment Composite Al ness ness Impact Ex. Grade Grade Grade(pbw) (pbw) (pbw) ρ_(th)) (° C.) (° C.) (% of ρ_(th)) (%) (Kg/mm) (GPa)Damage 1 F80  F400  F1500 55 35 15 73 1050 800 ~100 <2% ~1100 360 Slight2 F80  F400  F1500 55 35 15 72 1050 800 ~100 — ~1230 350 None 3 F500 F1500 — 30 70 — 70 1050 800 ~100 <2% 380 None Comp F80  F400  F1500 5535 15 73 None none ~100 ~20-25 ~290 280 None 1 Comp F1500 — — — — — — —— >98 N.A. 2800 410 Severe 2 SiC Comp α- — — — — — — — — >99.5 N.A. 1440370 Moderate 3 Al₂O₃ Grades of boron carbide available fromElektroschemeltzwerk Kempten, Munich Germany and Mudanjiang JingangzuanBoron Carbide Co., LTD. Severe = High deformation, lager impact sitedamage >5 mm, cracking noticeably separated part Moderate = Noticeabledeformation, large impact damage ~4 mm, cracking separated part Slight =Minimal deformation, small impact site damage ~2 mm, through cracks

What is claimed is:
 1. A method for preparing an aluminum-boron carbidecomposite, the method consisting of: a) forming a mixture of at leasttwo boron carbide particulates into a porous body that has a porosity ofat most 35% , wherein the at least two boron carbide particulates havedifferent average particle sizes, wherein the average size of the largerparticles is at least twice as large as the average size of the smallerparticles; and wherein prior to step (b) the boron carbide particulatesare heated to a temperature of 1200° C. to 1800° C. in a vacuum or inertatmosphere for one minute to 50 hours, b) infiltrating the porous bodywith aluminum or aluminum alloy until an infiltrated aluminum-boroncarbide body is formed that has at most 1% porosity, c) heat treatingthe infiltrated body for at least 25 hours at an AlB₂₄C₄ formingtemperature of 1000° C. to 1100° C. to form an aluminum boron carbidecomposite wherein AlB₂₄C₄ forms between the boron carbide particles andthereby bonds the boron carbide particles, which results in a continuousnetwork of AlB₂₄C₄ and boron carbide, and d) subsequent to step (c)heat-treating at an aluminum depleting temperature of 700° C. to 900° C.for a time to form the aluminum boron carbide composite having analuminum concentration of less than 2% by volume of said composite. 2.The method of claim 1, wherein the boron carbide particulates form aporous body having a specific surface area of at least 0.5 m²/g.
 3. Themethod of claim 2 wherein the boron carbide particulates have a weightratio of at least 1/1 of particles having particle diameter of greaterthan 50 micrometers to particles having a particle diameter less than 50micrometers.
 4. The method of claim 3 wherein the weight ratio is atleast 2/1.